Composite roll



April 25, 1939.

w. H. MELANEY COMPOSITE ROLL Filed July 19, 1938 Big. 1

2 Sheets-Sheet 1 D INVENTOR. m W

ATTORNEY.

April 25, 1939.

Filed July 19, 1938 W. H. MELANEY COMPOSITE ROLL 2 Sheets-Sheet 2 W IINVENTOR.

ATTORNEY.

Patented Apr. 25, 1939 UNITED STATES PATENT OFFICE 2 Claims.

This invention relates to new and useful improvements in chilled oralloy rolls for metal rolling mills, more particularly to the method ofmaking same, and it is among the objects thereof to provide a method ofmaking rolls for metal rolling mills of a composite metal to provide achilled body surface for the face of the roll of a dense hard or toughmetal and neck or journal portions of an easily machinable metal,whereby the costly machining and grinding operations incident to themanufacture of such rolls by methods heretofore practiced aresubstantially reduced.

A further object of the invention is to provide a composite metal rollin which the outer portions of the necks or bearings are constitutedpfprefabricated metal sleeves which are cast integrally with the main bodyof the rolls and which may be prepared in a manner to produce a fusionof substantial portions of the neck or hearing portions with the metalforming the main body of the rolls.

Still a further object of the invention is the provision of a metal rollin which the working body of the roll is cast of a tough or hard metaland in which the necks, bearings or driving portions are partiallyconstituted by preformed sleeve castings and partially of poured metalof different characteristics than the preformed sleeve pori'ill tions,the main body, the sleeve portions, and

the metal joining the sleeve and main body portions being integrallyformed by casting.

These and other objects of the invention will become more apparent'froma consideration of 35 the accompanying drawings constituting a parthereof in which like reference characters designate like parts and inwhich:

Fig. 1 is .a vertical cross-sectional view of a mold for casting rollsfor metal rolling mills em- 40 bodying the principles of this invention;

Fig. 2 a view partially in section and partially in side elevation of apreformed sleeve which is adapted to be joined integrally with the neckportion of the roll;

45 Fig. 3 a vertgal cross-sectional view of a preformed sleeve havingthe inner wall surface thereofv provided with annular serrations;

Fig. 4 a transverse section taken along the lines 4-4, Fig. 1; e

50 Fig. 5 a similar section showing a different form of serrations;

Fig. 6 a vertical cross-sectional view of a mold for casting rollsembodying a modified form of the invention;

Fig. 7 a side elevational view of a neck of varying insert for use inthe method of making rolls by the apparatus shown in Fig. 6; and

Fig. 8 a vertical cross-sectional view of the mold shown in Fig. '7.

With reference to Fig. 1 of the drawings, the numeral I designates ametal mold having an interior matrix surface 2 corresponding to thecontour of the main body portion of the roll to be cast, the metal moldquickly chilling the casting to a substantial depth to constitute a veryhard rolling surface, which is finished by a grinding or machiningoperation. The numeral 3 and numerals 4 and 5 designate mold sections orflasks for receiving sand 6, the top portion being molded to form asink-head l and the bottom portion of the sand mold is gated to adownrunner 8 through whichthe metal is poured, the gate Q'being disposedto produce a tangential flow of metal which sets up a swirling motion tothe molten metal as it enters the mold. 2o

Numerals Ill and II constitute the neck or bearing portions of the rolland the numerals l2 and I3 the Wobbler ends. The neck portions II and I2are formed of prefabricated sleeves I4, Figs. 2 and 3, the sleeve inFig. 2 being provided with serrations or flutes Ha as shown in Fig. 5,which are axially .disposed and the serrations or flutes l5, Fig. 3, areof annular form. These neck portions may be pickled, machined, orsandblasted or otherwise prepared to clean the inner surfaces and may becoated with a non-oxidizing or rust-preventing substance such as bygalvanizing or zinc coating before placing them in the sand portions, asshown in Fig. 1.

In casting the roll, the metal forming the main body portion of the rolldesignated by the numeral i6 is first poured into the down-runner 8andenters the base of the mold, filling the matrix portion thereof tojust above the top of Wobbler l2, the sink-head portion l remainingempty of metal. The metal thus initially poured into the mold is of acharacter suitable for the severe rolling operations to which the rollis subjected in rolling mill practice, and is chilled for a substantialdepth along the metallic matrix portion 2 as heretofore explained.

A softer or more readily machinable metal is then poured throughthe'runner 8 to displace only the molten metal of the down gate andsprue. The same metal isthen poured into the 6G sink-head I to feeddownwardly into the upper neck portion as the metal contracts in themain body portion of the roll for sinking purpose only.

When the metal is poured as described, it will fuse or melt the serratedportions Ma and I5,

as the case may be, to eflect an intimate welding of the preformed neckpieces with the adjacent cast or supporting body portion of the roll, itbeing obvious that the faces of the neck portions l3 may beotherwiseprepared to promote the welding action of the molten metal withthe preformed sleeve portions.

As shown in Fig. 2, the bottom' neck portion I3 is provided with a gatel1 and by employing metal of the same or similar properties as that ofwhich the neck pieces l3 are formed for the displacement of the metalfrom down gate and sprue only, initially poured to form the main body ofthe rolls, the gate I! will be of the same material as the sleeve I3, sothat the finished roll will have no hard spot on the fin ished surfaceof the neck or bearings.

In Fig. 6 of the drawings, neck or hearing sleeves I8 are provided withflanges l9 which extend into the matrix portion 2 of the mold in whichthe roll body is cast. Because of the swirling motion of the metalentering the bottom of the mold through the offset gate II, it will forma meniscus as shown at 20 and 2|, Fig. 6, all impurities of the metalaccumulating in the depressed portion at 22 and 23. As the metal rises,the metal at'the outer edge is free from impurities and when it reachesthe level above the flange I9 of the insert that forms the neck orbearing of the roll, it will flow in the annular space 24. As it risesfurther, as shown near the top of the roll body matrix 2, the samemeniscus effect is maintained so that pure metal will reach the annularspace 24a between the flange I9 and the roll body matrix. Otherwise, thepouring of the metal through the down-gate is the same as described inconnection with Fig. 1, the metal being filled to the top of the Wobblerl2. It is then displaced by softer metal of the character of the necksleeves 18 to an amount just sufficient to displace the metal in thegate ll of the sleeve portion so that upon subsequent machining therewill be no hard spots. in the neck or hearing portion. The same grade ofmetal is poured into the sink-head 1 to feed into the top of the castingwhen shrinkage takes place.

In Figs. Sand 8 I have shown the sleeve portions lined at 25 with sheet,copper, or other.

metal which may be coated with a flux so that when the molten metal ispoured into the mold it will be welded or brazed with the metal of thesleeves l8 through the fusing action of the lining 25. This is analternative method ofbonding the cast metal with the preformed sleevemembers to that employing the serrations or flutes of the sleeves shownin Figs. 2 and 3 of the drawings.

-By employing the flanged sleeves as shown in Fig. 6, the clear line ofdemarkation will result between the outer periphery of the flanges I9and the metal in the annular grooves 24 which will be immediatelyapparent when the neck and roll portions are machined and/or groundafter the casting operation.

Rolls cast as hereinbefore described have a main body portion 16 of avery hard or tough metal which may be finished by machining or grinding,whereas the neck portions l and II are of a softer material which may bereadily machined to size without requiring the long tedious grinding orother slow machining operations to reduce said parts to theirapproximate finished dimensions as in the manner of conventionalpractice, the elimination of which results in a very substantialreduction in the cost of machining these rolls.

Although several embodiments of the invention have been hereinillustrated and described, 20

it will be evident to those skilled in the art that variousmodifications may be made in the details of construction withoutdeparting from the principles herein set forth.

I claim:

1. The method of making rolls for metal rolling mills and the like whichcomprises providing a mold consisting of a metallic matrix portion forcasting the main body of the roll, sand portions adjacent tothe metalbody portion for casting the necks and Wobblers of the roll and a downgate and sprue for one of the sand portions, placing sleeve portions ofpreformed metal in the sand portions of the molds to form the outerportions of the necks thereof, pouring molten metal in the bottom of themold to form the main body of the roll, displacing said cast fluid metalfrom the down-gate and sprue of the mold by fluid metal of the characterof the preformed sleeve portions, and pouringmetal similar to the metalof the sleeve portions in the sink-head at the top of the mold to flllthe void caused by shrinkage in the main body portion Y of the mold.

2. The method of making rolls for metal rolling mills and the like whichcomprises the steps of inserting prefabricated sleeve portions in a moldadjacent the main body chill, the sleeve portions having fluted innersurfaces constituting passages for the molten metal poured in the mold,pouring the metal for the main body portion into the mold to completelyflll the mold in contact with the fluted surfaces of the prefabricatedsleeve portions to thereby melt the fluted surfaces of the sleeveportions to produce a fusing of the molten metal with the metal of theprefabricated sleeve portions.

WILLIAM H. MELANEY.

GERTIFiGATE 0F .CORRECTION.

ia'ten t No. 2,155,610. April 25; 19 9.

HILLIAM H. mum.

' It is hereby certified, that error appears in the -fmintedspecification of the'above numbered pa'tent requiring correctionasfollows: Page 1, second column, lines 32 and 35, strike out the words"such as by galvanizing or zinc coating"; and that the and LettersPatent should be read with this correction therein that the same mayconferm'to the record of the case in the Patent Office.

Signed and sealed this 1st day of August, A. D. 1939,,

- Henry Wm Arrmdale (Seal) Acting Gomissiener ex" Patents,

